American Amir Aboutaleb

Gear Manufacturers Vice President of

AGMA’s Technical
Association Division

Peer-reviewed technical papers to be featured

at AGMA’s Fall Technical Meeting
The AGMA Fall Technical Meeting (FTM) is the premier techni-
cal forum in the United States to hear and discuss the latest applied
research in the gear industry. This year, we will have 27 presenta-
tions in five sessions: Efficiency, Lubrication, Noise, and Vibration;
Manufacturing, Inspection, and Quality Control; Application,
Design, and Rating; Materials and Heat Treatment; and Gear Wear
and Failure. We solicited more than 50 peer reviewers from across the
globe to assist us in evaluating all papers in a thorough double-blind
review process. All technical papers are published by AGMA and are
later indexed in Scopus, the largest abstract and citation database of
peer-reviewed literature: scientific journals, books, and conference
proceedings. FTM attendees will receive PDF copies of all technical
papers from the sessions for which they registered.
Some highlights for this year’s compelling research include a pre-
sentation by Dr. Franco Concli from the University of Bozen on CFD
Simulation of Power Losses and Lubricant Flows in Gearboxes. His paper
describes the application of computational fluid dynamics simulations
of power losses and lubricant flows in gearboxes. In addition, we have
Mr. Irebert Delgado, a researcher at NASA, who will present his recent
test results on The Effectiveness of Shrouding on Reducing Meshed
Spur Gear Power Loss. Lastly, Dr. Hermann Stadtfeld of the Gleason
Corporation will present Psychoacoustic Methodology for the Noise
Reduction of Bevel Gearsets.
In addition to the 24 technical papers being presented, I would like
to bring attention to three invited special presentations: Dr. David
Talbot from The Ohio State University will be presenting Indexing
Error and Dynamic Factors of Spur Gears, focusing on the relation-
ship between dynamic factor, gear quality, and pitch line velocity. Our
second invited speaker is Dr. Peter Glaws from TimkenSteel. He will
present The Link Between Steel Cleanness Measurement and Gear Life
Performance. His talk may assist designers, especially because the need
for light weighting and increased power are ever-present in so many
of our end-user markets. Our third special guest will be Raymond
J. Drago, P.E. of Drive Systems Technology Inc., Mechanical Power
Transmission Consultants. Ray is a well-known presence in the gear
industry and has been a prominent instructor for AGMA for many
years. He will present Reverse Gear Systems Engineering — Why,
When & How — Avoiding Pitfalls … and Litigation! This presenta-
tion will be relevant to many in our industry.
I would like to thank the reviewers, as well as the AGMA
Technical Division Executive Committee, chaired by Todd Praneis
from Cotta Transmission Company, LLC, for all its hard work
over the last several months in bringing us the high-caliber
presentations that have become expected of the AGMA FTM.
I encourage all gear industry engineers and technical experts to
attend this event. The format allows for a level of interaction
between presenters and attendees that is unique to the industry. I
always enjoy the Q&A periods at the end of each session, as they
are very informative.
This year’s Fall Technical Meeting is October 22–24 in Columbus,
Ohio, and immediately precedes Gear Expo 2017, both located at
the Greater Columbus Convention Center. FTM attendees also will
receive admission to the Gear Expo show floor, where they can see
more than 200 exhibitors, special keynote presentations, and so much
more. I look forward to seeing you in Columbus this October.
A full list of presentations is available in this AGMA section of
Gear Solutions, and presenter bios also can be found on the AGMA
website at www.agma.org.

Session I
Efficiency, Lubrication, Noise, and Vibration
CFD Simulation of Power Losses
and Lubricant Flows in Gearboxes
Dr. Franco Concli, University of Bozen (Italy)
This paper describes the application of
Computational Fluid Dynamics simulation of power
losses and lubricant flows in gearboxes based
on an original global re-meshing technique. This
enables accurate predictions in relatively short
simulation times, compatible with the industrial
design practice. The results of the practical
applications used for the validation also are
included and discussed in the paper.
Understanding the Dynamic Influences
of Gear Oils and Radial Shaft Seals
Joe Walker, Freudenberg-NOK Sealing Technologies and
Craig Desrochers, P.E., Klüber Lubrication
Approximately 40 percent of long-term gearbox
leakages can be traced back to poor interaction
between the Radial Shaft Seal (RSS) and the
lubricant. This paper highlights the most critical
interactions between the industry’s most commonly
used gear oil formulations with emphasis on synthetic
oils with Nitrile and Fluoroelastomers. Through an
ideal combination of base oil and additives, the
demand of life expectancy on the radial shaft seals
can be met.
Gear Tooth Strength Analysis of High
Pressure Angle Cylindrical Gears
Dr. Alfonso Fuentes, Rochester Institute of Technology
In this paper, the gear tooth strength of high
pressure angle gears is studied and compared
with that of conventional pressure angle gears. The
comparison will be performed regarding contact
pressure, contact and bending stresses, loaded
function of transmission errors, and comparison of

AUGUST  2017 17
errors of alignment and shift of contact pattern when
mounted in similar shafts.
The Effectiveness of Shrouding
on Reducing Meshed Spur Gear Power
Loss — Test Results
Irebert Delgado, NASA
Reducing power losses to rotorcraft gearboxes, due
to windage drag and viscous effects on rotating,
meshed gear components would allow gains in areas
such as vehicle payload, range, mission type, and
fuel consumption. One method used in rotorcraft
gearbox design attempts to reduce losses is to use
close clearance walls to enclose the gears in both the
axial and radial directions. This paper examines using
meshed spur gears at four shroud configurations and
compares the data to available data.
Session II
Manufacturing, Inspection, and
Quality Control
Complete Measurement of Gearbox
Components
Dr. Christof Gorgels, Klingelnberg
In today’s production environment, a variety of
different measurement devices, such as CMMs,
gear checkers, form testers, and roughness testers,
are used to assess the quality and accuracy of
workpieces, many of which require specialized
training and environments. This paper describes how
a Circular CMM (CCMM) can be integrated into a
production environment. The benefits and challenges
of the use of a CCMM will be discussed.
The Effect of Asymmetric Cutter Tip Radii
on Gear Tooth Root Bending Stress
Dr. Nihat Yildirim, Gaziantep University (Turkey)
The tooth root fillet is where the maximum bending
stress concentration region is located during torque
transmission via gear pairs. An increase in gear root
fillet radius provides a smooth transition from involute
to trochoid, increases root critical section thickness,
and the moment of inertia against bending of tooth.
A 10-percent to 11-percent reduction in bending
stress is obtained by using asymmetric cutter tip radii
coefficients for two sides of the gear tooth profile with
standard center distance and no tooth interference.
Magnetic Barkhausen Noise as an
Alternative to Nital Etch for the Detection
of Grinding Burn on Gears
James Thomas and Stephen Kendrish, American Stress
Technologies, Inc.
Magnetic Barkhausen Noise (MBN) is quantitative,
repeatable, and non-destructive. Further, the MBN
method is easily automated, thus removing operator
influence as seen with Nital Etch, as a variable. Using
a sample set of carburized spur gears ground to
varying conditions of grinding burn, the MBN method
American
Gear Manufacturers
18
Association
gearsolutions.com
is demonstrated to match or exceed the detection
effectiveness of traditional Nital Etch. Residual stress
depth distributions measured with X-ray diffraction
and electrochemical layer removal are utilized as a
quantitative verification method.
Areal Evaluation of Involute Gear Flanks
with Three-Dimensional Surface Data
Yue Peng, University of North Carolina at Charlotte
This paper presents the benefits of areal evaluation
of gear flanks, mathematical approaches for areal
description of involute surface, deviations and
modifications, and the characterization of areal data
with “3D gear deviation parameters.” Approximation
and orthogonal polynomial decomposition methods
are applied for surface reconstruction and parameter
calculation. Both simulated and measured gear data
are analyzed, and comparisons with conventional
evaluation results are presented.
Standard Samples for Grinder Burn
Etch Testing
Jonathan Crow, Caterpillar Inc.
This paper discusses a unique method for producing
a standard sample of an acid etch system that has
a consistent amount of thermal damage. Multiple
degrees of burn are applied to the sample to ensure
that the etch inspection can detect all levels of
potential burn on the piece parts. The sample can
then be reliably used to test an acid etch system and
its method to ensure the proper amount of contrast
for threshold levels of thermal damage.
Psychoacoustic Methodology for the
Noise Reduction of Bevel Gearsets
Dr. Hermann Stadtfeld, Gleason Corporation
A rather exciting conclusion from the psychoacoustic
research is the proposal of a gear transmission graph,
which is a hybrid that connects different mathematical
functions within the one pitch long contact area and
the outside of this area. The results show that the
hybrid transmission function dramatically changes the
way bevel and hypoid gearsets will be optimized in the
future for silent operation.
Session III
Application, Design, and Rating
FE-based Method for Design
of Robust Tooth Flank Modifications
for Cylindrical and Planetary Gear Stages
in Consideration of Manufacturing
Tolerances
Julian Theling, M.Sc., Laboratory of Machine Tools and
Production Engineering (WZL) of RWTH Aachen, Chair of
Machine Tools
The authors present a method to evaluate the
quality and stability of flank modifications regarding
manufacturing tolerances during the design process,
using an FE-based tooth contact analysis. The
presented design process provides a method to
examine and simulate characteristics of the excitation
behavior and durability of a gear pair. This enables the
engineer to choose the most robust micro-geometry
in terms of quality and stability already in the design
process.
Reliability, Lifetime, and Safety Factors
Dr. Stefan Beermann, KISSsoft AG
This paper uses several examples to show the
practical differences in using safety factors versus
reliabilities. The failure probability of all components
for a specific lifetime is calculated to provide the
reliability of the whole gearbox as a system of
components. This provides the engineer an easier
method to compare designs and identify the critical
components.
A Comparison of Current AGMA, ISO,
and API Gear Rating Methods
John M. Rinaldo, Atlas Copco Comptec, LLC (retired)
There are many different gear rating methods
in use today, and they can give substantially
different results for any given gear set. This
paper will make it easy to understand the
choices and the impact the choices have on
gearbox design. The eight standards examined
are AGMA 2001, AGMA 6011, AGMA 6013, ISO
6336, API 613, API 617, API 672, and API 677.
This paper will provide a useful aid to customers
who are unsure of the differences between the
standards.
Prediction of Dynamic Factors for Helical
Gears in a High-Speed Multi-Body
Gearbox System
Niranjan Raghuraman, MS and Chad Glinsky, Romax
Technology
This paper will analyze the influence of operating
speed, torque, system dynamics, and gear micro-
geometry on the dynamic factors of a high-speed
gearbox. It will show that the dependence of dynamic
factor on torque is significant and must not be
ignored, and that the presence of system resonance
modes increases dynamic factors. The dynamic
factors calculated in this study are compared with the
dynamic factor values suggested by ISO and AGMA
standards.
SPECIAL PRESENTATION
Indexing Error and Dynamic Factors
of Spur Gears
Dr. David Talbot, The Ohio State University
According to ANSI/AGMA 2001-D04, dynamic factor
is directly related to gear quality and pitch line velocity.
This study uses a dynamic load distribution model
in order to assess the validity of this relationship and
investigate its physical source. Predictions of both
gear root stress and contact stress dynamic factor are
considered in the study.
Session IV
Materials and Heat Treatment
Fatigue Performance and Cleanliness
of Carburizing Steels for Gears
Lily Kamjou, MSc, Ovako
The cleanliness of steels used for gears is of great
importance when looking to improve life of gears
or increase loads. In this paper, carburizing steels
with the same basic chemical composition, but
with a varying cleanliness level, are compared. The
investigation showed a good qualitative correlation
between the fatigue performance and the inclusion
assessment made by ultrasonic evaluation and SEM.
The results also show that traditional micro-inclusion
rating methods are not sensitive enough to give a
good indication of material performance.
SPECIAL PRESENTATION
The Link Between Steel Cleanness
Measurement and Gear Life Performance
Dr. Peter C. Glaws, TimkenSteel
Several current industry material (cleanness)
standards were reviewed and found to have poor
correlation to gear fatigue performance. Possible
reasons for the lack of correlation are discussed.
Selected advanced cleanness measurement
methods and appropriate resulting metrics are
offered as alternatives, providing quantitative data
in a format that may be used as tools for gear
designers to improve gear reliability and highlight
potential for light weighting and increased power.
Predicting Life on Through Hardened
Steel Rack and Pinion for Jacking
Applications in the Offshore Industry
Dipl. Ing. (FH) Adrian Nowoisky, Oerlikon Fairfield
It is well known in the industry that, according to
AGMA and ISO gear calculation methods, the contact
stresses in rack and pinion systems for jack up
applications exceed the permissible limits by a factor
of 3 to 6. However, these applications have been in
service without any failures for more than 20 years.
This paper will outline the process of the analytical
evaluation of a specific design and validate it with
systems currently in service.
Four Ways Polyketone Polymers Can
Improve Gear Performance
Tim Morefield, Esprix Technologies
Historically, the most commonly specified resins
for plastic gears have been acetal (POM), nylon
(PA 66) and polyester (PBT), with or without
modifiers (PTFE, carbon fiber, glass fiber, silicone,
or combinations thereof) to reduce friction and
wear. Polyketone offers engineers four distinct
advantages relative to other materials in meeting
design challenges: 1) superior wear properties, 2)
better dimensional control/stability, 3) superior creep
rupture performance, and 4) quieter operation.
AGMA has over 1,000 Twitter followers! Join the conversation @agma
1001 N. Fairfax Street | Suite 500 | Alexandria, VA 22314 | (703) 684-0211 | www.agma.org
Effect of Non-Metallic Inclusions
on Bending Fatigue Performance
in High Strength 4140 Steel
Michael Burnett, TimkenSteel
This paper studies the fatigue performance of three
sets of quench and tempered 4140 steel samples,
representing three distinctly different inclusion
populations. The inclusion populations for each of
the sample sets were characterized using both an
SEM-based image analysis system, primarily for the
micro-inclusions, and a high-resolution UT system
for the macro-inclusions. The sample sets also were
evaluated using both longitudinal and transverse
specimens in all the bending fatigue tests. The results
of these tests will be presented.
Sensitivity Study of Press Quench
Process and Concept of Tooling Design
for Reduced Distortion by Modeling
Dr. Zhichao (Charlie) Li, DANTE Solutions Inc.
The press quench process includes parameters such
as heating rate, austenitization temperature, applied
load type, load amount, load locations from the tooling,
friction between the tooling and the gear, and the
quench rate. All these factors can lead to inconsistent
distortion, especially for the radial size of thin-wall gears.
In this paper, the effects of several critical factors on
the dimensional inconsistency and tooling design are
analyzed by heat treatment modeling software.
Session V
Gear Wear and Failure
Influences of the Residual Stress
Condition on the Load Carrying Capacity
of Case Hardened Gears
Dipl.-Ing. Christian Güntner, Gear Research Center (FZG) —
Technical University of Munich
Compressive residual stresses, such as those
generated by shot peening, result in an increased
tooth root bending strength. The author’s
investigations show that shot peening can increase
the load carrying capacity of case hardened gears
significantly. Correlations between the residual stress
state and the load carrying capacity limits were
determined. This paper will give an overview of the
main results of different investigations and discuss
influences of the residual stress condition on different
failure modes of case hardened gears.
Calculation of Tooth Flank Fracture Load
Capacity — Practical Applicability and
Main Influence Parameters
Dipl.-Ing. Michael Hein, Gear Research Center (FZG) —
Technical University of Munich
Due to improved material qualities, new surface
finishing methods, and increased heat-treatment
process reliability, flank surface damages, such as
pitting or micropitting, can increasingly be prevented
in a reliable manner. At the same time, this may
result in an increase of unexpected flank damages
such as tooth flank fracture. A computer-aided
calculation of the risk of tooth flank fracture damages
will be presented.
Full Contact Analysis Versus Standard
Load Capacity Calculation for Cylindrical
Gears
Dr.-Ing. Michael Otto, Gear Research Center (FZG) —
Technical University of Munich
In this paper, local tooth contact analysis and
standard calculation are used to determine the load
capacity for the failure modes pitting, tooth root
breakage, micropitting, and tooth flank breakage.
Analogies and differences between both the local and
the standard approaches are shown. The example
presented demonstrates a valid possibility to optimize
the gear design by using local tooth contact analysis
while satisfying the requirement of documenting the
load carrying capacity by standard calculations.
The Influence of a Grinding Notch
on the Gear Bending Strength Rating
Dr. Ulrich Kissling, KISSsoft AG
To achieve the requested quality, most gears today
are ground. If the gear is premanufactured with a tool
without protuberance, then at the position where the
grinding tool retracts from the flank, a grinding notch
in the tooth root area is produced. A review of the
formulas to calculate the effects of the grinding notch
is necessary. A 3D-FEM analysis that was used to
deduce an improved formula will be presented.
Gear Failure Analysis and Lessons
Learned Under Unanticipated Loading
Conditions
Dr. Anngwo Wang, MOOG Inc. Aircraft Group
Lessons about gear failure can be learned in the
development phases under unanticipated design or
manufacturing errors or unaccounted loading and
operating conditions. This paper will study 10 such
failure cases. Lessons learned are presented and
act as reminders not to overlook lightly loaded gears,
gears with deflection, or mounting problems and
unexpected issues from manufacturing errors.
SPECIAL PRESENTATION
Reverse Gear System Engineering — Why,
When & How — (Avoiding Pitfalls … and
Litigation!)
Raymond J. Drago, P. E., Drive Systems Technology, Inc.
Mechanical Power Transmission Consultants
Reverse engineering a gear system is a not too
unusual task, thus it is easy to become complacent.
Failure to fully follow best practices can result in, in
the worst cases, very expensive, time consuming, and
reputation damaging litigation. This presentation will
rely on the experience of being an expert witness to
provide information to aid the reverse engineering of a
project as completely as possible.
AUGUST  2017 19
 CALENDAR OF EVENTS
Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard
in the standards process, AGMA has something to offer you. If you would like more information on any of the
following events, visit www.agma.org or send an email to events@agma.org.
Events are open to AGMA members only. Not a member? Send an email to membership@agma.org.
August 29 — Helical Gear Rating Committee — subcommittee 925 — WebEx
AUGUST

August 30 — Bevel Gearing Committee Meeting — WebEx

August 31 — Helical Gear Rating Committee Meeting — WebEx

September 6-8 — Bevel Gear System Design — San Diego, California

September 7 — Wormgearing Committee Meeting — WebEx
September 12 — Enclosed Drive for Industrial Applications Committee Meeting — WebEx
September 13 — Powder Metallurgy Committee Meeting — WebEx
SEPTEMBER

September 14 — Lubrication Committee Meeting — WebEx

September 18-22 — Basic Training for Gear Manufacturing — Chicago, Illinois
September 19 — Materials & Metallurgy Committee Meeting — WebEx
September 21 — Accuracy Committee Meeting — WebEx
September 26 — Cutting Tools Committee Meeting — WebEx
September 27 — Sound & Vibration Committee Meeting — WebEx
September 28 — Helical Gear Rating Committee - Subcommittee 925 — WebEx

October 3 — Nomenclature Committee Meeting — WebEx

October 4-5 — Fall Marketing & Forecasting Meeting — Chicago, Illinois
OCTOBER

October 4-6 — Steels for Gear Application — Alexandria, Virginia

October 10 — Plastics Gearing Committee Meeting — WebEx
October 17 — Lubrication Committee Meeting — WebEx
October 19-20 — Aerospace Gearing Committee Meeting — Columbus, Ohio
October 22-24 — Fall Technical Meeting — Columbus, Ohio
October 24-26 — Gear Expo — Columbus, Ohio

AGMA LEADERSHIP

Jim Bregi: Chairman Nitin Chaphalkar: DMG Mori USA

EXECUTIVE COMMITTEE

Doppler Gear Company

Michael Engesser: Reishauer Corporation
John Cross: Treasurer
ASI Technologies Inc. David Long: Chalmers & Kubeck Inc.
BOARD OF DIRECTORS

John E. Grazia: Chairman, BMEC Michael McKernin: Circle Gear and Machine Company
GearTec Inc.
Todd Praneis: Chairman, TDEC Cory Ooyen: Global Gear & Machining, LLC
Cotta Transmission Company, LLC Carl D. Rapp: The Timken Company
Dean Burrows: Chairman Emeritus
Gear Motions Inc. Tania Sabados: Rapid Gear
Andrea Scanavini: Somaschini North America
Matt Croson: President
SENIOR STAFF

Greg Schulte: Bonfiglioli USA

Amir Aboutaleb: Vice President, Technical Division
Jenny Blackford: Vice President, Marketing Brian Schultz: Great Lakes Industry, Inc.
Jill Johnson: Director, Member Services George Thomas: Bison Gear & Engineering Corp.
Casandra D. Blassingame: Director, Education Hastings Wyman: Klingelnberg America, Inc.
General requests: website@agma.org | Membership questions: membership@agma.org | Gear Expo information: gearexpo@agma.org
Technical/Standards information: tech@agma.org | AGMA Foundation: foundation@agma.org

20 gearsolutions.com